Block for use in automated building construction

ABSTRACT

The present disclosure relates to the building industry and in particular to a block for use in automated building construction. In one aspect, the block comprises a generally cuboid body having a top and a base, a length extending between a pair of opposed ends, and a width extending between a pair of opposed sides; the body including a plurality of hollow cores extending from said top to said base, and arranged in a row between said opposed ends; wherein each core has a rectilinear cross-sectional shape; and wherein the thickness of the block between each pair of adjacent cores is at least double the thickness of the block on all other sides of each core, so that the block is divisible into a plurality of substantially identical block portions, each portion including four walls of substantially uniform wall thickness about its core.

PRIORITY DOCUMENTS

The present application claims priority from Australian ProvisionalApplication No. 2017904002 titled “BRICK FOR USE IN AUTOMATED BUILDINGCONSTRUCTION” and filed on 4 Oct. 2017, the content of which is herebyincorporated by reference in its entirety.

INCORPORATION BY REFERENCE

The following publication is referred to in the present application andits contents are hereby incorporated by reference in their entirety:

International Patent Application No. PCT/AU2017/050728 (WO/2018/009978)titled “ADHESIVE APPLICATOR AND OBJECT PLACING HEAD INCORPORATING THESAME” in the name of FASTBRICK IP Pty Ltd.

BACKGROUND OF THE INVENTION

The present disclosure relates to the building industry and inparticular to a block for use in automated building construction.

DESCRIPTION OF THE PRIOR ART

The reference in this specification to any prior publication (orinformation derived from it), or to any matter which is known, is not,and should not be taken as an acknowledgment or admission or any form ofsuggestion that the prior publication (or information derived from it)or known matter forms part of the common general knowledge in the fieldof endeavour to which this specification relates.

International Patent Application No. PCT/AU2017/050728 (WO/2018/009978)discloses a brick laying and adhesive applying head which is fitted toan articulated telescopingly extendable boom mounted on a truck, formingan automated brick laying machine. The brick laying and adhesiveapplying head applies adhesive to the brick, and comprises a robot whichlays the brick.

Many of the common clay bricks used in building construction inAustralia such as the Boral Maxi Brick, and Slick brick, are made usingtechniques that produce a poor tolerance of the bricks dimensions, withresultant variation between different bricks of length, height andwidth. This is acceptable in the construction of buildings usingcement-based mortars which are laid manually, as the builder/bricklayercan adjust for variations in brick dimensions, by varying the thicknessof adjoining beds of mortar as the bricks are laid. Common clay bricksare very dense, and consequently are difficult to machine. In additionto this, the size of these bricks is very small, which increases thenumber of handling operations in the construction of a building for agiven wall area, with a resultant reduction of efficiency. Overall thesefactors make these bricks unsuitable for use within automated buildingconstruction requiring close tolerances in building construction.

Another block on the market that could overcome some of the problems inautomated building construction is the Porotherm clay brick supplied byWienerberger A.G. While the Porotherm clay brick has a precise height,it has an irregular width and length. The Porotherm external andinternal bricks do not tie in with each other, resulting in complexjoins between internal and external walls. While not an insurmountableproblem, the standard size of the Porotherm does not work well with thecurrent standard Australian door frame width and height sizes. Thesefactors produce a large amount of waste when using the Porotherm systemin the Australian construction industry. The Porotherm clay bricks arealso very fragile. In addition to this, the shape and features of thePorotherm clay brick do not allow for easy recognition using machinevision techniques.

An alternative to the above described bricks and blocks is the CSR HebelPowerBlock product. This is a solid brick formed of moulded aeratedconcrete. While supplied in various large format sizes which wouldrender it suitable for use in automated building construction, theinventor has found that the need for post manufacturing processing andthe tendency of the supplied bricks to warp, renders these bricks lessthan ideal for use with the inventor's automated building constructionsystem.

It is against this background, and the problems and difficultiesassociated therewith, that the present invention has been developed.

SUMMARY OF THE PRESENT INVENTION

In one broad form, the present invention seeks to provide a block foruse in automated building construction, the block comprising a generallycuboid body having:

-   -   a) a top and a base;    -   b) a length extending between a pair of opposed ends;    -   c) a width extending between a pair of opposed sides;    -   d) a plurality of hollow cores extending from said top to said        base, and arranged in a row between said opposed ends; wherein        each core has a rectilinear cross-sectional shape; and,    -   wherein the thickness of the block between each pair of adjacent        cores is at least double the thickness of the block on all other        sides of each core, so that the block is divisible into a        plurality of substantially identical block portions of        rectilinear cross-sectional shape, each portion including four        walls of substantially uniform wall thickness about its core.

That is to say, the cuboid body comprises six rectangular faces at rightangles to each other.

In one embodiment, the walls extending about the cores are substantiallysolid.

In one embodiment, the walls extending about the cores include aplurality of secondary cores extending from said top to said base, thesecondary cores separated by a plurality of webs.

In this way, the block is lightened by the inclusion of the secondarycores, but sufficient strength and rigidity is maintained by the webs.

In one embodiment, the block includes four hollow cores, so as to bedivisible into four substantially identical block portions.

In one embodiment, the cores comprise at least one of:

-   -   a) a square cross-sectional shape; and,    -   b) a rectangular cross-sectional shape.

In one embodiment, the block is for use in constructing an externalwall, the block having:

-   -   a) a length of approximately 490 mm;    -   b) a width of approximately 240 mm; and,    -   c) a height of approximately 230 mm.

In one embodiment, the block has a dry mass of approximately 17 to 22kg.

In one embodiment, the block is for use in constructing an internalwall, the block having:

-   -   a) a length of approximately 490 mm;    -   b) a width of approximately 115 mm; and,    -   c) a height of approximately 230 mm.

In one embodiment, the block has a dry mass of approximately 10 to 14kg.

In one embodiment, the block further includes at least one slot locatedbetween each pair of adjacent cores, each slot extending from said topto said base, and transversely across said block; wherein the slotsdelineate the plurality of substantially identical block portions.

In one embodiment, two or more slots are located between a pair ofadjacent cores to delineate two block portions, these slots are alignedtransversely across the block, and separated by one or more webs.

In one embodiment, the slots are spaced substantially equidistantlongitudinally, from each adjacent hollow core.

In one embodiment, the slots are spaced substantially equidistant fromeach other and from the opposed ends.

In one embodiment, each slot is located in a predetermined positiondenoting where the block is intended to be cut. The spacing of the slotsin the block defines positions where the block may be trimmed.

In one embodiment, each hollow core is spaced evenly from each of theopposed sides, and the hollow cores adjacent each end are spaced evenlytherefrom.

In one embodiment, the block includes on the top thereof, a transverserectangular recess located extending across each hollow core between theopposed sides, to accommodate a rectangular-section tie plate extendinginto the hollow core and across part of the transverse rectangularrecess.

In one embodiment, the block includes on the top thereof, at least onelongitudinal rectangular recess spaced from the opposed sides bysubstantially the same distance as the spacing of the transverserectangular recess from the nearest of the opposed ends or a slotlocated between adjacent cores, to accommodate a rectangular-section tieplate extending into the hollow core and across part of the longitudinalrectangular recess.

In one embodiment, the block includes at least one tongue located at oneof the opposed ends, and at least one groove located at the other of theopposed ends, each groove being provided to at least partiallyaccommodate a tongue of an adjacent one of the blocks.

In one embodiment, each tongue and each groove extend vertically fromthe top to the base of the block.

In one embodiment, the block includes an aperture extending into theblock, located on the top proximal to the tongue, to provide a referencepoint to identify the tongue end of the block in a machine visionsystem.

In one embodiment, the block includes a bevel located extending aroundat least some edges of at least one of the top, base or vertical sideedges of the block.

In one embodiment, the block includes a rectangular section recesslocated extending along longitudinal edges of at least one of the top,base or vertical side edges of the block.

In one embodiment, the block includes a bevel located along externaledges not having a rectangular section recess.

In one embodiment, the block is manufactured from a mixture including atleast:

-   -   a) water;    -   b) cement; and,    -   c) a lightweight expanded aggregate.

In one embodiment, the lightweight expanded aggregate is at least oneof:

-   -   a) an expanded clay aggregate;    -   b) an expanded slate aggregate;    -   c) an expanded shale aggregate; and,    -   d) an expanded glass aggregate.

In one embodiment, the mixture further includes a plasticiser.

In one embodiment, the mixture further includes a fine aggregate.

In one embodiment, the mixture includes:

-   -   a) water;    -   b) cement;    -   c) lightweight expanded clay aggregate (LECA);    -   d) a fine aggregate; and,    -   e) a plasticiser.

In one embodiment, the cement is a high early strength (HE) cement.

In one embodiment, the fine aggregate is quarry dust.

In one embodiment, the plasticiser is MasterGlenium® SKY8100.

In one embodiment, the LECA particles used in the mixture have adiameter of at least one of 0 mm-1 mm, 1 mm-2 mm, 2 mm-3 mm, 3-4 mm, 4mm-5 mm, 5 mm-6 mm, 7 mm-8 mm, 8 mm-9 mm and 9 mm-10 mm.

In another broad form, the present invention seeks to provide a blockportion divided from one of the hereinbefore described blocks, by a cutmade at a midpoint between adjacent cores.

In another broad form, the present invention seeks to provide a buildingsystem using the hereinbefore described blocks, wherein the blocks areprovided in two sizes having a first width and a second width twice thatof the first width plus the thickness of the spacing between the blocks.

In another broad form, the present invention seeks to provide a wallassembly including a plurality of the hereinbefore described blocks laidin a plurality of courses, and an adhesive applied between each courseof blocks and a successive course to bond these.

In one embodiment, the adhesive is machine applied to the base of ablock before it is laid onto a lower course.

In one embodiment, at least two parallel beads of adhesive are appliedonto the base of a block along a lengthwise extent thereof.

In one embodiment, the adhesive is further applied onto one or more endfaces of a block so as to form a perp joint with an adjacent block in acourse.

In one embodiment, the adhesive is one of:

-   -   a) Huntsman Suprasec® 7273; and,    -   b) Selleys Aquadhere Durabond®.

In one embodiment, the wall assembly further includes one or more blockportions divided from the block or a remainder thereof by a cut made ata midpoint between adjacent cores.

In one embodiment, the wall assembly is assembled using a plurality offirst blocks having a first width and a plurality of second blockshaving a second width twice that of said first width plus the thicknessof the spacing between the blocks.

In one embodiment, the first blocks are internal blocks that are usedsubstantially in the construction of internal walls and the secondblocks are external blocks that are used substantially in theconstruction of external walls.

In one embodiment, internal walls are tied into external walls byinserting internal blocks between adjacent external blocks for at leastalternating courses of blocks so that ends of the internal blocks layflush with an outer face of an external wall.

In one embodiment, internal walls are tied into external walls byforming a cut-out in an inner face of at least some external blocks andlocating an internal block into the cut-out to thereby interlock theblocks.

In one embodiment, internal walls are tied into external walls by tieclips used in at least some of the courses.

In one embodiment, internal walls are tied into external walls so thatoverlapping hollow cores of respective internal and external blocks aresubstantially aligned.

In one embodiment, the wall assembly further includes a render appliedto at least external surfaces thereof.

In one embodiment, the render is an acrylic non-porous render to seal awall from moisture ingress.

In another broad form, an aspect of the present invention seeks toprovide method of manufacturing a hereinbefore described block, themethod including the steps of:

-   -   a) producing a batch mixture including:        -   i) water;        -   ii) cement;        -   iii) a lightweight expanded aggregate;        -   iv) a fine aggregate; and,        -   v) a plasticiser.    -   b) pouring the mixture into a mould; and,    -   c) using dry vibration pressing to form a plurality of blocks        from the mixture.

In one embodiment, the lightweight expanded aggregate is a lightweightexpanded clay aggregate (LECA).

In one embodiment, the fine aggregate is quarry dust.

In one embodiment, the plasticiser is MasterGlenium® SKY8100.

According to a further aspect, there is provided a block for automatedbuilding construction, said block having a body with a top and a base,said body having a length extending between opposed ends, and a widthextending between opposed sides; said body having a plurality of hollowcores extending from said top to said base; wherein each said hollowcore extends across at least half of said width, and is spacedsubstantially evenly from said opposed sides, and said hollow cores arespaced apart substantially evenly from each other along said length,said hollow cores extending in single file between said opposed ends;wherein said body has a slot located between each said hollow coreextending transversely across said block to an extent commensurate withthe transverse extent of said hollow cores, said slots each having awidth of no greater than one fifth of the longitudinal extent of saidhollow cores.

In one embodiment, said slots do not have any portion that impinges afacing surface of said block.

In one embodiment, said slots are spaced substantially equidistantlongitudinally, from each said hollow core.

In one embodiment, said slots are spaced substantially equidistant fromeach other and from said opposed ends. The slots may notionally dividethe block into fractions, for example in the most preferred embodiment,into quarters, so that a cut block can be divided into a quarter lengthand three quarter length blocks or two half length blocks. Alternativelythe block could be longer and dividable into fifths or sixths.

In one embodiment, the slots have a width commensurate with thethickness of a cutting blade or slightly less and are provided to speedthe process of cutting through a block.

In one embodiment, the slots have a width of no more than three timesthe thickness of a cutting blade. This would provide a recess for anytongue in an end of a said block to nest after a cut has been madethrough such a slot. In addition, where a cut brick has the cut edgeexposed, there would not be a great amount of filler such as plaster orrender required to fill any recess, in order to make the finished wallsmooth. In practice the slot width could be anywhere from just under thecutting blade thickness to a maximum of two and a half centimetres or aninch, in order to achieve an objective of minimising the amount ofdebris produced by cutting a block at the slot width location, andminimising the amount of filler required to cover an exposed cut in afinished wall. The most preferred slot width is from half a centimetreup to one centimetre.

In one embodiment, the slots taper in width, all being narrower andshorter at one of the top (or bottom) of the block and wider and longerall at the bottom (or top) of the block. The taper may range from 0.05°upward but anywhere in the range of 0.1° to 1.0° is practical. Thehollow cores may also possess a similar taper, extending in the same wayas the slot taper. The blocks may be formed in a mould with taperedinserts formed of a “slippery” plastic material such as polyethylene,placed into the mould in the positions where the hollow cores and slotsare located. Aerated concrete (possibly including aggregate of lowdensity material) or other settable material is poured or packed intothe mould to form the block, and once the settable material has hardenedor cured, the mould is disassembled to reveal the block. The taperedinserts are then driven out of the block, with the taper assisting intheir removal without causing cracking.

In one embodiment, the hollow cores are each of square section.

In one embodiment, said hollow cores are each of rectangular section. Inone form, the hollow cores have rounded corners.

In one embodiment, each said hollow core is spaced evenly from each ofsaid opposed sides and said hollow cores adjacent each end are spacedevenly therefrom.

In one embodiment, there is a single hollow core extending across saidwidth between each said slot and said opposed ends, and between eachsaid slot. In a wider brick there may be more than one hollow core, saytwo hollow cores, located side by side across said width between eachsaid slot and said opposed ends, and between each said slot, but inpractice, this would be expected to lead to unwarranted manufacturingcomplexity.

In the arrangement as described, each slot is located in a predeterminedposition where the block is intended to be cut to length. In one formthere will be four hollow cores and three slots in each block. However,there could be a greater number of hollow cores and slots if required.

In one embodiment, said hollow cores are rectangular and have internalwalls spaced from each other double the distance as the spacing from asaid internal wall to the closest of said opposed ends or said opposedsides.

In one aspect, there is provided a block having substantially the samewidth as the spacing between adjacent slots, which can be used as ablock for constructing an internal wall, and also in a second preferredembodiment a block having substantially double the width as the spacingbetween adjacent slots, which can be used as a block for constructing anexternal wall. Note that in both of these embodiments the longitudinalslot spacing is identical.

In one embodiment, the hollow core longitudinal spacing of said firstembodiment and said second embodiment is identical.

In one embodiment, said block includes on the top thereof, a transverserectangular recess located extending across each said hollow corebetween said opposed sides, to accommodate a rectangular-section tieplate extending into said hollow core and across part of said transverserectangular recess. The rectangular-section tie plate would in practise,tie adjacent courses of intersecting wall sections during constructionof a building. The transverse rectangular recess need only be as deep asthe thickness of the rectangular-section of the tie plate, or could beslightly less than this where the adhesive bonding successive coursesspaces the bricks from each other.

In one embodiment, said block includes on the top thereof, at least onelongitudinal rectangular recess spaced from said opposed sides bysubstantially the same distance as the spacing of a said transverserectangular recess from the nearest of said opposed ends or a said slot,to accommodate a rectangular-section tie plate extending into saidhollow core and across part of said longitudinal rectangular recess.With this arrangement, in a block having the same width as the spacingbetween adjacent slots, the longitudinal rectangular recess will extendcentrally along the top of the block. In a block having double the widthas the spacing between adjacent slots, there may be only twolongitudinal rectangular recesses, each spaced from the nearest of saidopposed sides by substantially the same distance as the spacing of asaid transverse rectangular recess from the nearest of said opposed endsor a said slot.

With the above described arrangement, in a system of blocks having twopreferred embodiments as described, with four spaced hollow coresseparated by three slots, the ends of the blocks can intersect in fourpredetermined positions along the sides of adjoining blocks, and can besecured by a rectangular-section tie plate extending between adjacenthollow cores of adjoining blocks, with the rectangular-section tie platebeing accommodated within a part of the transverse and/or longitudinalrecess as the case may be. In one form, said block includes at least onetongue located at one of said opposed ends and at least one groovelocated at the other of said opposed ends, each said groove beingprovided to at least partially accommodate a said tongue of an adjacentone of said blocks.

In one embodiment, each said tongue and each said groove extendvertically from top to bottom of said block.

In one embodiment, said block has one said tongue and one said groove.

In one embodiment, said block includes an aperture extending into saidblock, located on the top proximal to said tongue. This apertureprovides a reference point to identify the tongue end of the block in amachine vision system.

In one embodiment, said block includes a bevel located extending alonglongitudinal edges of said base.

In one embodiment, said block includes a bevel located extending alonglongitudinal edges of said top.

In one embodiment, said block includes a bevel located extending aroundthe periphery of said top.

In one embodiment, said block includes a bevel located extending aroundthe periphery of said base.

In one embodiment, said block includes a bevel located extending alongexternal vertical edges.

In one embodiment, said block includes a rectangular section recesslocated extending along longitudinal edges of said base.

In one embodiment, said block includes a rectangular section recesslocated extending along longitudinal edges of said top.

In one embodiment, said block includes a rectangular section recesslocated extending along external vertical edges.

In one embodiment, said block includes a bevel located along externaledges not having a square section recess.

In one embodiment, the rectangular section recess may include ledgeextents of up to ⅜ of an inch or 10 mm, 5/16 of an inch or 8 mm, ¼ of aninch or 6 mm, 3 mm, 4 mm, 4.5 mm or 5 mm.

Also in accordance with the invention there is provided a buildingsystem using blocks as hereinbefore described, wherein said slots arespaced substantially equidistant from each other and from said opposedends, and the distance between adjacent said slots is equal to saidwidth.

Also in accordance with the invention there is provided a buildingsystem using blocks as hereinbefore described, wherein said slots arespaced equidistant from each other and from said opposed ends, and thedistance between adjacent said slots is equal to half of said width.

Yet further, in accordance with the invention there is provided abuilding system using blocks as hereinbefore described, wherein saidblocks are provided in two sizes having a first width and a second widthtwice that of said first width, wherein said blocks are provided allhaving said slots spaced substantially equidistant from each other andfrom said opposed ends, and the distance between adjacent said slots isequal to said first width.

The block may be provided in any length being twice the first width orlonger but in first width increments, plus the thickness of the spacingbetween the bricks.

In a further aspect, there is provided a block portion divided from oneof the above described blocks, by a cut made at a midpoint betweenadjacent cores.

In a further aspect, there is provided a wall assembly comprised of aplurality of the above described blocks laid in a plurality of courses,and an adhesive applied between each course of blocks and a successivecourse to bond these.

In one embodiment, the wall assembly further comprises one or more blockportions divided from a remainder of one of the blocks by a cut made ata midpoint between adjacent cores.

In one embodiment, this cut is made at one of the slots (whereprovided).

In one embodiment, the wall assembly further comprises a render appliedto at least one side thereof.

It will be appreciated that the broad forms of the invention and theirrespective features can be used in conjunction, interchangeably and/orindependently, and reference to separate broad forms is not intended tobe limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples of the present invention will now be described with referenceto the accompanying drawings, in which:

FIG. 1 is an isometric view of a block according to a first embodiment;

FIG. 2 is a top plan view of the block of FIG. 1 ;

FIG. 3 is an isometric view of the block of FIG. 1 ;

FIG. 4 is a bottom plan view of the block of FIG. 1 ;

FIG. 5 is a right side plan view of the block of FIG. 1 ;

FIG. 6 is a front plan view of the block of FIG. 1 ;

FIG. 7 is a rear plan view of the block of FIG. 1 ;

FIG. 8 is an isometric view a block according to a second embodiment;

FIG. 9 is a top plan view of the block of FIG. 8 ;

FIG. 10 is an isometric view of the block of FIG. 8 ;

FIG. 11 is a bottom plan view of the block of FIG. 8 ;

FIG. 12 is a right side plan view of the block of FIG. 8 ;

FIG. 13 is a front plan view of the block of FIG. 8 ;

FIG. 14 is a rear plan view of the block of FIG. 8 ;

FIG. 15 is a top plan view of a block according to the first embodimenttrimmed to three quarter length;

FIG. 16 is a top plan view of a block according to the first embodimenttrimmed to half length;

FIG. 17 is a top plan view of a block according to the first embodimenttrimmed to quarter length;

FIG. 18 is a top plan view of a block according to the second embodimenttrimmed to three quarter length;

FIG. 19 is a top plan view of a block according to the second embodimenttrimmed to half length;

FIG. 20 is a top plan view of a block according to the second embodimenttrimmed to quarter length;

FIG. 21 is a top plan view of two blocks according to the secondembodiment, showing end to end nesting;

FIG. 22 is an isometric view showing a brick tie clip for use witheither embodiment;

FIG. 23 is a top plan view of the two blocks according to the secondembodiment shown in FIG. 21 , and an intersecting block according to thefirst embodiment secured with the brick tie clip of FIG. 22 ;

FIG. 24 is an isometric view of the arrangement shown in FIG. 23 ;

FIG. 25 is a side view of the arrangement shown in FIG. 23 , lookingtoward the end of the intersecting block according to the firstembodiment;

FIG. 26 is a cross-section through A-A in FIG. 25 ;

FIG. 27 is a close-up cross-section showing Detail A of FIG. 26 ;

FIG. 28 is a tie down bracket of the threaded type for use with blocksaccording to the first embodiment;

FIG. 29 is a tie down bracket of the threaded type for use with blocksaccording to the second embodiment;

FIG. 30 is a tie down bracket of the slotted type for use with blocksaccording to the second embodiment;

FIG. 31 is a side view showing the tie down bracket of FIG. 29 securinga roof truss;

FIG. 32 is an exploded view showing assembly of tie down brackets withincourses of bricks, for use in securing a roof truss;

FIGS. 33 and 34 are isometric views of an alternative embodiment of theblock shown in FIGS. 1 to 7 ;

FIGS. 35 and 36 are isometric views of another alternative embodiment ofthe block shown in FIGS. 1 to 7 ;

FIGS. 37 and 38 are isometric views of yet another alternativeembodiment of the block shown in FIGS. 1 to 7 ;

FIGS. 39 and 40 are isometric views of a further alternative embodimentof the block shown in FIGS. 1 to 7 ;

FIGS. 41 and 42 are isometric views of yet a further alternativeembodiment of the block shown in FIGS. 1 to 7 ;

FIGS. 43 and 44 are isometric views of an alternative embodiment of theblock shown in FIGS. 8 to 14 ;

FIGS. 45 and 46 are isometric views of another alternative embodiment ofthe block shown in FIGS. 8 to 14 ;

FIGS. 47 and 48 are isometric views of yet another alternativeembodiment of the block shown in FIGS. 8 to 14 ;

FIGS. 49 and 50 are isometric views of a further alternative embodimentof the block shown in FIGS. 8 to 14 ;

FIGS. 51 and 52 are isometric views of yet a further alternativeembodiment of the block shown in FIGS. 8 to 14 ;

FIG. 53 is an isometric view of a block according to a furtherembodiment;

FIG. 54 is a top plan view of the block of FIG. 53 ;

FIG. 55 is an isometric view of a block according to a furtherembodiment;

FIG. 56 is a top plan view of the block of FIG. 55 ;

FIG. 57 is an end view of an external wall assembly;

FIG. 58 is an end view of an internal wall assembly;

FIGS. 59 and 60 are isometric views of a block according to a furtherembodiment;

FIGS. 61 and 62 are isometric views of a block according to a furtherembodiment;

FIGS. 63 and 64 are isometric views of a block according to a furtherembodiment;

FIGS. 65 and 66 are isometric views of a block according to a furtherembodiment;

FIG. 67 is an isometric view of a block according to a furtherembodiment;

FIG. 68 is a top view of the block according to FIG. 67 ;

FIGS. 69 and 70 are isometric views of a block according to a furtherembodiment;

FIGS. 71 and 72 are isometric views of a block according to a furtherembodiment;

FIGS. 73 and 74 are isometric views of a block according to a furtherembodiment;

FIGS. 75 and 76 are isometric views of a block according to a furtherembodiment;

FIG. 77 is an isometric view of a block according to a furtherembodiment;

FIG. 78 is a top view of the block according to FIG. 77 ;

FIG. 79 is an isometric view of a block according to a furtherembodiment;

FIG. 80 is a top view of the block according to FIG. 79 ;

FIG. 81 is a perspective view of an interlocking joint arrangementbetween an external block and an internal block;

FIG. 82 is an exploded view of the interlocking joint arrangement ofFIG. 81 ;

FIG. 83 is a perspective view of part of a wall assembly showing anintersection between an internal wall and an external wall;

FIG. 84 is a plan view of the wall assembly of FIG. 83 ; and,

FIG. 85 is an exterior view of the wall assembly of FIG. 83 .

In the following description, like reference characters designate likeor corresponding parts throughout the Figures.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An example of a block 11 for automated building construction shall nowbe described with reference to FIGS. 1 to 7 .

In this example, the block 11 comprises a generally cuboid body 15having a top 17 and a base 19, a length extending between a pair ofopposed ends 21, 23 and a width extending between a pair of opposedsides 37, 39. The body 16 further includes a plurality of hollow cores41, 43, 45, 47 extending from said top 17 to said base 19, and arrangedin a row between said opposed ends 21, 23 wherein each core 41, 43, 45,47 has a rectilinear cross-sectional shape. The thickness of the block11 between each pair of adjacent cores 41, 43, 45, 47 is at least doublethe thickness of the block 11 on all other sides of each core 41, 43,45, 47, so that the block 11 is divisible into a plurality ofsubstantially identical block portions of rectilinear cross-sectionalshape, each portion including four walls of substantially uniform wallthickness about its core 41, 43, 45, 47.

The above described arrangement provides a number of advantages.

Firstly, the ability to divide the block into a plurality ofsubstantially identical block portions enables the block to be cut intoa number of usable elements, each of which may be used as a constructionelement in a building wall. This substantially reduces building wasteand allows all off-cuts to be used. Indeed, the entire building designcan be based on a grid system defined by the size of the smallest usableblock portion. The useful ability to divide the block into furtherusable block portions is enabled by the relative thickness betweenadjacent cores compared to the thickness of the block on all other sidesof the core (which is nominally double). This thickness ensures that theremaining block portion has sufficient strength once it has been trimmedfor use in the overall building structure.

A number of further features will now be described.

In one example, the walls extending about the cores are substantiallysolid (for example for a concrete masonry unit (CMU) block. However, inother examples the walls extending about the cores include a pluralityof secondary cores extending from said top to said base, the secondarycores separated by a plurality of webs. The secondary cores (i.e.extrusion coring) may assist in reducing the weight of the block and mayalso form a complex pathway for the ingress of water through or acrossthe block. Such a block may be manufactured from clay for example. Asthe size of clay blocks is typically variable within the same batch,when not using mortar, the top and bottom and possibly ends of the blockmay need to be rectified to produce a consistent size necessary forautomated building construction using adhesive instead of mortar.

Typically, the block includes four hollow cores so as to be divisibleinto four substantially identical block portions. This enables the blockto be divided into quarter length, half length and three quarter lengthblock portions. In another example, the block may include three cores soas to be divisible into three substantially identical block portions.This enables the block to be divided into one third and two third lengthportions. The block may also include one of five, six, seven, eight,nine or even ten cores so as to be divisible into many different numberof substantially identical block portions.

Typically, the cores comprise at least one of a square cross-sectionalshape; and, a rectangular cross-sectional shape, although this is notessential and circular or oval shaped cores could also be provided.

In the example shown in FIGS. 1 to 7 , the block is for use inconstructing an internal wall, the block having a length ofapproximately 490 mm; a width of approximately 115 mm; and, a height ofapproximately 230 mm. The block has a dry mass of approximately 10 to 14kg.

In another example, a wider block is employed for use in constructing anexternal wall, the block having a length of approximately 490 mm; awidth of approximately 240 mm; and, a height of approximately 230 mm. Inthis example, the block may have a dry mass of approximately 17 to 22kg. The block in either example is a large block compared to a standardclay brick for example that is commonly used in the constructionindustry. The size of the block combined with the relatively low massmakes it suitable for use in automated building construction. The sizemeans that relatively fewer blocks are required to be handled and therelatively low mass reduces the payload that the robot is required tocarry which results in less structural load/stress and dynamicdisturbance in the system meaning that the block can be positioned withhigher accuracy.

In one example, the block further includes at least one slot locatedbetween each pair of adjacent cores, each slot extending from said topto said base, and transversely across said block, wherein the slotsdelineate the plurality of substantially identical block portions. Inthis way, each slot is located in a predetermined position denotingwhere the block is intended to be cut. The slots provide a cutting guidefor a saw blade or the like and typically each slot is at least thewidth of a cutting blade.

In the case of a clay block as previously described, two or more slotsmay be located between a pair of adjacent cores to delineate two blockportions, these slots are aligned transversely across the block, andseparated by one or more webs. As with the secondary cores, the two ormore slots may assist in forming a tortuous path for water transferthrough or across the block.

Preferably, the slots are spaced substantially equidistantlongitudinally, from each adjacent hollow core. Furthermore, the slotsare typically spaced substantially equidistant from each other and fromthe opposed ends.

In one example, each hollow core is spaced evenly from each of theopposed sides, and the hollow cores adjacent each end are spaced evenlytherefrom. This provides overall symmetry to the block which enables itto be laid in any orientation (i.e. there is no distinction betweeneither end or side).

In some examples, tie plates are used to tie together adjoining wallsmade from the blocks. In particular, the block may include on the topthereof, a transverse rectangular recess located extending across eachhollow core between the opposed sides, to accommodate arectangular-section tie plate extending into the hollow core and acrosspart of the transverse rectangular recess.

Furthermore, the block may include on the top thereof, at least onelongitudinal rectangular recess spaced from the opposed sides bysubstantially the same distance as the spacing of the transverserectangular recess from the nearest of the opposed ends or a slotlocated between adjacent cores, to accommodate a rectangular-section tieplate extending into the hollow core and across part of the longitudinalrectangular recess. The tie plates may tie together external andinternal walls, although the use of tie plates is not essential andother means for interlocking or ‘keying in’ the walls may be used aswill be further described.

In one example, the block includes at least one tongue located at one ofthe opposed ends, and at least one groove located at the other of theopposed ends, each groove being provided to at least partiallyaccommodate a tongue of an adjacent one of the blocks. Typically, eachtongue and each groove extend vertically from the top to the base of theblock. The tongue and groove arrangement is used to interlock adjacentblocks to one another which provides a resulting wall with increasedflexural strength and also ensures that there are no gaps between theperpends. Although such an interlocking arrangement would be beneficial,it does make automated brick laying more difficult as machine visionsystems are required to correctly orient the block the right way andlaying tolerances become much tighter to avoid laying collisions betweenadjacent blocks. Nevertheless, in one example, the block includes anaperture extending into the block, located on the top proximal to thetongue, to provide a reference point to identify the tongue end of theblock in a machine vision system.

In some examples, the block includes a bevel located extending around atleast some edges of at least one of the top, base or vertical side edgesof the block.

The block may further include a rectangular section recess locatedextending along longitudinal edges of at least one of the top, base orvertical side edges of the block.

In yet a further example, the block includes a bevel located alongexternal edges not having a rectangular section recess.

The composition of the block will now be described in some more detail.Whilst a clay block is envisaged as previously described, the followingdiscussion will focus on the manufacture of a CMU block. Whilst a blockmade from aerated concrete has been envisaged, it has been found that animproved CMU block for use in automated building construction may beattained wherein the block is manufactured from a mixture including atleast water; cement (such as high early strength (HE) cement); and, alightweight expanded aggregate.

The light expanded aggregate enables a concrete block of significantsize to be manufactured whilst minimising its weight and density as faras possible to make it suitable for use by an automated brick layingmachine which imposes weight constraints on the block (e.g. less than20-23 kg).

The lightweight expanded aggregate may be selected from at least one ofan expanded clay aggregate, an expanded slate aggregate, an expandedshale aggregate, and, an expanded glass aggregate. Most preferably,lightweight expanded clay aggregate (LECA) is used as a course aggregatein the mixture which in addition to reducing weight in the block alsoimproves the insulation characteristics of the block.

Typically, the mixture further includes a fine aggregate such as quarrydust or sand which fills up small cavities and holes.

In addition, it has been found to be preferably to add a plasticiserinto the mixture which provides elasticity and helps to keep everythingtogether when wet. The plasticiser allows more concrete to be used andless water which increases strength while reducing weight. Aparticularly preferred plasticiser used is MasterGlenium® SKY8100manufactured by BASF although other suitable plasticiser having similarproperties to this may be used instead and this example is not intendedto be limiting.

Accordingly, in one preferred mixture there includes water, cement (e.g.HE cement), lightweight expanded clay aggregate (LECA); a fine aggregate(such as sand or quarry dust) and, a plasticiser (such as MasterGlenium®SKY8100).

In one example, the LECA particles used in the mixture have a diameterof at least one of 0 mm-1 mm, 1 mm-2 mm, 2 mm-3 mm, 3-4 mm, 4 mm-5 mm, 5mm-6 mm, 7 mm-8 mm, 8 mm-9 mm and 9 mm-10 mm.

In one particularly preferred recipe, the above ingredients are mixedtogether to form a batch mixture in the following amounts: at least 70 Lof water (typically more than 100 L), 0.4 m³ of LECA particles having adiameter of between 0 mm-4 mm, 0.5 m³ of LECA particles having adiameter of between 4 mm-8 mm, 0.15 m³ of quarry dust, 0.175 m³ of HEcement; and, 900 mL of MasterGlenium® SKY8100.

In a further aspect, there is provided a block portion divided from oneof the blocks by a cut made at a midpoint between adjacent cores.

In another aspect, there is provided a building system using theaforementioned blocks, said blocks provided in two sizes having a firstwidth and a second width twice that of said first width plus thethickness of the spacing between the blocks. The block having the firstwidth is an internal block used in the construction of internal walls,whilst the block having the second width is an external block used inthe construction of external walls. The second width ensures that wheninternal and external blocks are in abutment, the cores of each blockwill be in alignment.

According to a further aspect, there is provided a wall assemblyincluding a plurality of the aforementioned blocks laid in a pluralityof courses, and an adhesive applied between each course of blocks and asuccessive course to bond these. In this regard, it is to be appreciatedthat the adhesive is machine applied to the base of a block before it islaid onto a lower course. At least two parallel beads of adhesive aretypically applied onto the base of a block along a lengthwise extentthereof.

In a further example, the adhesive is further applied onto one or moreend faces of a block so as to form a perp joint with an adjacent blockin a course. By gluing the perps, flexural strength of the wall isincreased which makes the structure more suitable for use in cyclonerated areas. In other examples, there is no adhesive between the perpsas application of such is more difficult in the context of an automaticbricklaying machine.

Particularly preferred examples of a suitable adhesive include HuntsmanSuprasec® 7273, and Selleys Aquadhere Durabond®. These adhesives aremoisture curing, high strength, polyurethane construction adhesives andit will be appreciated that other similar adhesives may also be used andthese examples are not intended to be limiting.

In one example, the wall assembly includes one or more block portionsdivided from the block or a remainder thereof by a cut made at amidpoint between adjacent cores. As previously described, a grid systemmay be used in the design of the wall based around the size of thesmallest divisible block portion which enables every block portion to beused in the construction of the wall with no building waste.

Typically, the wall assembly is assembled using a plurality of firstblocks having a first width and a plurality of second blocks having asecond width twice that of said first width plus the thickness of thespacing between the blocks. As previously described, the first blocksare internal blocks that are used substantially in the construction ofinternal walls and the second blocks are external blocks that are usedsubstantially in the construction of external walls.

In one example, internal walls are tied into external walls by insertinginternal blocks between adjacent external blocks for at leastalternating courses of blocks so that ends of the internal blocks layflush with an outer face of an external wall. Alternatively, internalwalls are tied into external walls by forming a cut-out in an inner faceof at least some external blocks and locating an internal block into thecut-out to thereby interlock the blocks.

In a further example and as previously mentioned, internal walls may betied into external walls by tie clips used in at least some of thecourses.

In the above examples, it is preferable that internal walls are tiedinto external walls so that overlapping hollow cores of respectiveinternal and external blocks are substantially aligned. This enables thecores of the wall system to be used as conduits for services etc. aspreviously described.

In one example, the wall assembly further includes a render applied toat least external surfaces thereof. Preferably, the render is an acrylicnon-porous render to seal a wall from moisture ingress. A wall made fromCMU blocks which are very porous will typically require a render whilsta wall made from clay blocks may or may not require a render. The renderfurther serves to tie the wall structure together and thereby acts as anexternal skin. Particularly in examples where the perps are not glued,the render covers these gaps in the structure. In addition, the renderalso blocks ultraviolet (UV) light, thereby preventing it from damagingthe adhesive between courses of blocks.

A suitable acrylic render is Rockcoat PM100 Quick Render which iscurrently used in construction. It will be appreciated that any othersimilar acrylic render could also be used and this is not intended to belimiting.

Finally, in another aspect there is provided a method of manufacturing ablock for use in automated construction including the steps of producinga batch mixture including: water, cement (such as HE cement), alightweight expanded aggregate (such as LECA), a fine aggregate (such asquarry dust); and, a plasticiser (such as MasterGlenium® SKY8100). Themethod further includes pouring the mixture into a mould and using dryvibration pressing to form a plurality of blocks from the mixture.

Referring now to the Figures, several illustrated embodiments of a blockfor use in automated building construction will be described in furtherdetail.

The blocks 11 illustrated in FIGS. 1 to 7 are intended for theconstruction of internal walls, and the blocks 13 illustrated in FIGS. 8to 14 are intended for the construction of external walls. In oneexample, each block 11, 13 has a moulded body 15 formed in a mould fromaerated concrete. The body 15 has a top 17 and a base 19, and has anominal length of approximately 50 cm between opposed ends 21 and 23.End 21 has a protruding tongue 25 extending between and from the top 17substantially to the base 19. End 23 has a recess 27 also extendingbetween and from the top 17 substantially to the base 19. The recess 27may partially accommodate a tongue 25 of an adjacently placed block inend 23 to end 21 alignment as shown in FIG. 21 , and the purpose of thisinterengagement is to prevent passage of light through the small spacebetween the ends 21 and 23 of adjacently placed blocks and also toincrease the flexural strength of an assembled wall. The tongue 25 has aflat surface 29 extending parallel to the surface of the end 21 of theblocks 11 and 13, with sloping ramp surfaces 31 extending either sidedown from the surface 29 to the surface of the end 21. The arrangementof the recess 27 is similar, with a flat recessed surface 33 extendingparallel to the surface of the end 23 of the blocks 11 and 13, withsloping ramp surfaces 35 extending either side from the surface 33 up tothe surface of the end 23. As the specific detail of the tongue 25 andgroove 27 shape is not particularly important, these details are shownnumbered only in FIG. 2 .

The block 11 has a width of approximately 12.5 cm extending betweenopposed sides 37 and 39 and the block 13 has a width of approximately 25cm extending between opposed sides 37 and 39. The overall height fromtop 17 to base 19 of both blocks 11 and 13 is approximately 25 cm. Theseblocks are large format blocks, intended for handling by brick layingmachines and in particular robotic brick laying machines, and as largeformat blocks, will weigh much more than conventional bricks used inmanual brick laying in the building industry.

Each block 11 and 13 has four hollow cores 41, 43, 45, 47 extending fromthe top 17 to the base 19, and in the block 11 extending across abouthalf of the width of the block 11, and in the block 13 extending acrossabout three quarters of the width of the block 13. These hollow cores41, 43, 45, 47 provide an air pocket for insulation and can be used asconduits for carrying services in a building constructed with the blocks11 and 13. They can also be used to carry reinforcing rods and haveconcrete poured down them for added strength. The hollow cores 41, 43,45, 47 are spaced from the sides 37 and 39 to provide a wall thicknessof about 3 cm in both blocks 11 and 13. The hollow cores 41, 43, 45, 47are spaced apart from each other evenly along the length of the blockand the cores 41 and 47 have a nominal wall thickness at their adjacentrespective ends 21 and 23 of about 3 cm. The hollow cores 41, 43, 45, 47are rectangular with rounded internal corners (square with roundedinternal corners in block 11). The hollow cores 41, 43, 45, 47 may havea 0.1° to 0.5° draft (or taper) for ease of manufacture with a mould.

The body 11 and 13 has three slots 51, 53, 55 extending from the top 17to the base 19, extending normally to the length of the block, and inthe block 11 extending across half of its width and in the block 13extending across three quarters of its width. The slots 51, 53, 55 arespaced from the sides 37 and 39 to provide a wall thickness of about 3cm in both blocks 11 and 13. The slots 51, 53, 55 also have a 0.1° to0.5° draft (or taper) for ease of manufacture with a mould.

Slot 51 is located between hollow cores 41 and 43. Slot 53 is locatedbetween hollow cores 43 and 45. Slot 55 is located between hollow cores45 and 47. The spacing between each slot and adjacent hollow coreprovides a substantially uniform wall thickness about the cores of about3 cm. In one example, the hollow cores 41, 43, 45, 47 and slots 51, 53,55 are formed using tapered inserts that are placed in the mould priorto the aerated concrete being introduced into the mould, before beingallowed to cure to a hardness sufficient to allow the tapered inserts tobe driven or pressed out, after the mould has been disassembled.

The slots 51, 53, 55 are spaced substantially equidistant from eachother and from said opposed ends, and provide a cross section throughwhich the block 11 and 13 may be cut with a power saw. The cut proceedsthrough a slot 51, 53 or 55 and the effect is to minimise the amount ofmaterial that the power saw blade must traverse. This reduces the amountof dust generated by cutting through the brick in these positions, whichreduces the amount of waste that must be taken away from the site anddisposed of. The cut can be slightly offset to any slot so that a recessresults that can partially accommodate a tongue 25 of an adjacentlyplaced block. The spacing of the slots 51, 53, 55 is such that itdivides the block 11 and 13 into four nominally 12.5 cm long portions.

In the arrangement as described, each slot is located in a predeterminedposition where the block is intended to be cut to length. Thus a blockmay be cut into lengths of 12.5 cm, 25 cm and 37.5 cm, as shown in FIGS.15 to 20 . FIG. 15 shows a block 11 cut to three quarter length bycutting through slot 51. FIG. 16 shows a block 11 cut to half length bycutting through slot 53. FIG. 17 shows a block 11 cut to quarter lengthby cutting through slot 55. FIG. 18 shows a block 13 cut to threequarter length by cutting through slot 51. FIG. 19 shows a block 13 cutto half length by cutting through slot 53. FIG. 20 shows a block 13 cutto quarter length by cutting through slot 55.

Each block 11 and 13 includes on the top 17 thereof, a transverserectangular recess 61, 63, 65, 67 located extending across each hollowcore 41, 43, 45, 47 between the opposed sides 37 and 39.

The block 11 includes on the top 17 thereof, a longitudinal rectangularrecess 69. The longitudinal rectangular recess 69 spaced from an opposedside 37 or 39 by substantially the same distance as the spacing of anytransverse rectangular recess 61, 63, 65, 67 from the nearest of anopposed end 21 or 23 or any slot 51, 53 or 55.

The block 13 includes on the top 17 thereof, two parallel longitudinalrectangular recesses 71 and 73. These longitudinal rectangular recesses71 and 73 are spaced from their nearest side 37 or 39 by substantiallythe same distance as the spacing of any transverse rectangular recess61, 63, 65, 67 from the nearest of an opposed end 21 or 23 or any slot51, 53 or 55.

These rectangular recesses 61, 63, 65, 67, 69, 71 and 73 are provided toaccommodate a rectangular-section tie plate 75 having downwardlyextending legs 77 that extend into any juxtaposed hollow core and acrosspart of a rectangular recess that is adjacent to the hollow core that adownwardly extending leg extends into.

The sizes of the blocks and the positioning of the slots 51, 53 and 55are configured so that a building can be constructed so that therectangular recesses will align, and the tie plates 75 used at eachintersection of each course to tie the courses together. Therectangular-section tie plate would in practise, tie adjacent courses ofintersecting wall sections during construction of a building. Thetransverse rectangular recess need only be as deep as the thickness ofthe rectangular-section of the tie plate, or could be slightly less thanthis where the adhesive bonding successive courses spaces the bricksfrom each other.

Each block 11 and 13 includes an aperture 79 extending partially intothe block, located on the top 17 proximal to and spaced from the tongue25. This aperture 79 provides a reference point to identify the tongueend 21 of the block 11 and 13 in a machine vision system.

Each block 11 and 13 includes a bevel 81 located extending entirelyaround the periphery of the base 19, including through the tongue 25 andrecess 27. The purpose of the bevel 81 on the bottom periphery of theblock is to reduce the chipping of the block during transport,manufacture, handling and when being placed. In this example, the top ofthe block does not contain the bevel so the block orientation can berecognised by a machine vision system. In an alternative embodiment, thetop of the block may also have bevelled edges, but then the machinevision system would be reliant on determining orientation by identifyingthe aperture 79 and rectangular recesses 61, 63, 65, 67, and 69 or 71and 73. In other arrangements, the block is designed to have symmetry(with no cuts and no tongue and groove) so that it can be laid in anylengthwise orientation.

The blocks 11 and 13 are configured to assemble in a grid system,comprising a 125 mm square grid. The bounding box of each block 11 and13 is nominally 500 mm long and can be cut into a ¼, ½ or ¾ lengths, andbe placed on the grid. Internal walls constructed of blocks 11 can tieto external walls constructed of blocks 13 in any position correspondingto a core of the external wall, as is illustrated in FIGS. 23 and 24 .The advantage of using such a grid system is that waste is completelyeliminated as any remaining off cut of a trimmed block is of a usefullength and can therefore be used elsewhere in the building. The gridsystem increases the efficiency of the design process and the buildingprocess. Each block 11 and 13 is slightly smaller than the bounding boxof the grid system to create space for render to stick to the walls.Once the render is applied, the overall dimensions of the walls willfill the 125 mm square grid.

The rectangular recesses 61, 63, 65, 67, and 69 or 71 and 73 alsoaccommodate tie down brackets 83, 85, or 87 as illustrated in FIGS. 28to 30 . These tie down brackets have a main body 89 with a centrallylocated elongate aperture 91 or a threaded aperture 93 (or hole for aself-tapping screw). Arms 93 extend centrally to be accommodated inrectangular recesses 61, 63, 65, or 67, and 69, and arms 95 extendeither side to be accommodated in rectangular recesses 71 and 73. Themain body 89 is located in the appropriate sized hollow core 41, 43, 45,47 in the required position where a roof truss 97 or other buildingelement is to locate, on top of a course of bricks, before one of morecourses is overlaid. When the roof truss 97 or other building element isto be secured, it is located and secured to its bracket 99 and athreaded rod 101 passes down into the threaded aperture 93 or a rod 103with transverse bar 105 is inserted into the elongate aperture 91,depending on the tie down bracket 85 or 87 that has been used.

The embodiment illustrated in FIGS. 33 and 34 has the same features asthe embodiment illustrated in FIGS. 1 to 7 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending around the vertical edges and top ofboth sides 37 and 39, is provided with a 45 degree bevel 111 extendingalong the vertical edges of both sides 37 and 39, and along the top ofboth sides 37 and 39. The bevels 81 and 111 each have a transverseextent (length along the hypotenuse) of 1 cm.

The embodiment illustrated in FIGS. 35 and 36 has the same features asthe embodiment illustrated in FIGS. 1 to 7 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending along the top of both sides 37 and 39,is provided with a square section step 113 extending along the top ofboth sides 37 and 39. The bevels 81 each have a transverse extent of 1cm, and the square section step 113 has dimensions of 1.25 cm depth×1.25cm high (half an inch by half an inch). The square section step forms agroove in a feature brick wall which mimics or can be used for bed tuckpointing, in a completed wall.

The embodiment illustrated in FIGS. 37 and 38 has the same features asthe embodiment illustrated in FIGS. 1 to 7 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending along the vertical edges and along thetop of both sides 37 and 39, is provided with a square section step 113extending along the top of both sides 37 and 39, and a 45 degree bevel111 extending along the vertical edges of both sides 37 and 39. Thebevels 81 and 111 each have a transverse extent of 1 cm, and the squaresection step 113 has dimensions of 1.25 cm depth×1.25 cm high (half aninch by half an inch).

The embodiment illustrated in FIGS. 39 and 40 has the same features asthe embodiment illustrated in FIGS. 1 to 7 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending along the vertical edges and along thetop of both sides 37 and 39, is provided with a square section step 113extending along the vertical edges and along the top of both sides 37and 39. The bevels 81 each have a transverse extent of 1 cm, and thesquare section step 113 has dimensions of 1.25 cm depth×1.25 cm high(half an inch by half an inch).

The embodiment illustrated in FIGS. 41 and 42 has the same features asthe embodiment illustrated in FIGS. 1 to 7 , but does not have the 45degree bevel 81 extending around the periphery of the base 19, insteadhaving sharp edges 115 extending along the vertical transverse edges ofthe base 19, and is provided with a square section step 113 extendingall around the periphery of both sides 37 and 39. The square sectionstep 113 has dimensions of 1.25 cm depth×1.25 cm high (half an inch byhalf an inch).

The embodiment illustrated in FIGS. 43 and 44 has the same features asthe embodiment illustrated in FIGS. 8 to 14 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending around the vertical edges and top ofboth sides 37 and 39, is provided with a 45 degree bevel 111 extendingalong the vertical edges of both sides 37 and 39, and along the top ofboth sides 37 and 39. The bevels 81 and 111 each have a transverseextent of 1 cm.

The embodiment illustrated in FIGS. 45 and 46 has the same features asthe embodiment illustrated in FIGS. 8 to 14 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending along the top of both sides 37 and 39,is provided with a square section step 113 extending along the top ofboth sides 37 and 39. The bevels 81 each have a transverse extent of 1cm, and the square section step 113 has dimensions of 1.25 cm depth×1.25cm high (half an inch by half an inch).

The embodiment illustrated in FIGS. 47 and 48 has the same features asthe embodiment illustrated in FIGS. 8 to 14 , but in addition to the 45degree bevel 81 extending around the periphery of the base 19, insteadof having sharp edges extending along the vertical edges and along thetop of both sides 37 and 39, is provided with a square section step 113extending along the top of both sides 37 and 39, and a 45 degree bevel111 extending along the vertical edges of both sides 37 and 39. Thebevels 81 and 111 each have a transverse extent of 1 cm, and the squaresection step 113 has dimensions of 1.25 cm depth×1.25 cm high (half aninch by half an inch).

The embodiment illustrated in FIGS. 49 and 50 has the same features asthe embodiment illustrated in FIGS. 8 to 14 , with the 45 degree bevel81 extending entirely around the periphery of the base 19. Further,instead of having sharp edges extending along the vertical edges andalong the top of both sides 37 and 39, the block 11 is provided with asquare section step 113 extending along the vertical edges and along thetop of both sides 37 and 39. The bevels 81 each have a transverse extentof 1 cm, and the square section step 113 has dimensions of 1.25 cmdepth×1.25 cm high (half an inch by half an inch).

The embodiment illustrated in FIGS. 51 and 52 has the same features asthe embodiment illustrated in FIGS. 8 to 14 , but does not have the 45degree bevel 81 extending around the periphery of the base 19, insteadhaving a square section step 113 extending along all edges, all aroundthe periphery of both sides 37 and 39, and along the top and bottom ofboth ends 21 and 23. The square section step 113 has dimensions of 1.25cm depth×1.25 cm high (half an inch by half an inch).

In these embodiments, the square section step can be altered to beanywhere between 0.5 cm in height up to 1.25 cm high. The depth could bevaried down to 1 cm or even 0.75 cm or 0.5 cm. The provision of squaresection assists in disguising slight misalignment of the blocks in aconstruction, in addition to providing a feature effect, such asimitation mortar joins or tuck pointing. Where a completed wall is to berendered or coated, the square section step provides a purchase for thecoating, which assists its adhesion, particularly over the passage oftime, where due to cycles of heating and cooling, and under influence ofvibration, such coatings may detach from an entirely smooth wall.

Referring now to FIGS. 53 and 54 , where there is illustrated a block200 comprising square cores 202, but which differs from previouslypresented embodiments in that the walls extending about the cores 202comprise a plurality of secondary cores 210 (also of squarecross-sectional shape) extending from said top to said base, which areseparated by a plurality of webs 212. In this way, the block 200 islightened by the inclusion of the secondary cores, but sufficientstrength and rigidity is maintained by the webs 212. The secondary cores210 also provide a complex passage for water transfer across or throughthe block.

Moreover, three slots 220 are located between each pair of adjacentcores 202 to delineate block portions, where these slots 220 are alignedtransversely across the block. Each two adjacent block portions areconnected by four webs 222, which delineate these slots 220. Cuttingthrough these webs 222 is easier than cutting through solid block, sodivision of block portions can be effected considerably faster.

Referring now to FIGS. 55 and 56 , where there is illustrated a block300 comprising rectangular cores 302, and walls extending about thecores 302 comprising a plurality of secondary cores 310 (some of whichhave a rectangular cross-sectional shape). Five slots 320 are locatedbetween each pair of adjacent cores to delineate block portions, wherethese slots 320 are aligned transversely across the block. Each twoadjacent block portions are connected by six webs 322, which delineatethese slots 320.

The blocks 200, 300 denote an example of a block manufactured from claythat is suitable for use in automated building construction. In order toreduce the weight of the clay block a greater number of extrusion coresare required (the CMU block achieves its lightweight properties as aresult of the lightweight expanded aggregate which is added into themixture). The secondary cores also aid in preventing moisture ingressthrough or across the block meaning that the clay block may be usedwithout a render. The dimensions of clay blocks 200, 300 are nominallythe same as the CMU blocks previously described. Block 200 may have alength of approximately 490 mm; a width of approximately 115 mm; and, aheight of approximately 230 mm. Whereas block 300 may have a length ofapproximately 490 mm; a width of approximately 240 mm; and, a height ofapproximately 230 mm.

Referring now to FIG. 57 , where there is illustrated a wall assembly400 atop a slab of reinforced concrete 402. The wall assembly 400includes an external wall that is comprised of a plurality of the blocks13 laid in a plurality of courses, with an adhesive 421 applied betweeneach course of blocks 13 and a successive course to bond these, and arender 422 applied to both sides thereof. The wall assembly 400 furtherincludes an internal wall 420 comprised of a plurality of the blocks 11laid in a plurality of courses, with an adhesive 421 applied betweeneach course of blocks 11 and a successive course to bond these, and arender 422 optionally applied to one or both sides thereof.

FIGS. 59 through 66 illustrate ‘slot-less’ embodiments of the block withcores 41, 43, 45 and 47 of square cross-sectional shape. That is to say,none of these embodiments of the block comprise the slots 51, 53 or 55.With cores 41, 43, 45 and 47 of square cross-sectional shape, these thenare the block intended for use in internal walls. Each of these blocksis divisible into a plurality of substantially identical block portionsof rectilinear cross-sectional shape, each portion comprising four wallsof substantially uniform wall thickness about its core.

FIGS. 67 through 76 illustrate ‘slot-less’ embodiments of the block withcores of rectangular cross-sectional shape. That is to say, none ofthese embodiments of the block comprise the slots 51, 53 or 55. Withcores of rectangular cross-sectional shape, these then are the blocksintended for use in external walls.

Each of the embodiments of the block illustrated in FIGS. 59 through 76comprise different combinations of the bevels 81 and steps 113 describedand identified with the same reference numerals above, so these will notbe described again in detail here, to avoid repetition.

Referring now to FIGS. 77 to 80 , further examples of a preferred blockfor automated building construction are illustrated. In FIGS. 77 to 78 ,a block 11 for an internal wall is shown. The block 11 is similar to theinternal blocks previously described including recessed grooves 61, 63,65, 67, 69 for tie down clips. In this example, the block 11 has abevelled edge around the entire perimeter of the top face. Also shown islongitudinally extending slot 90 which extends centrally along the blockand which is an artefact of the moulding process. A block 13 of similardesign having bevelled edges around the entire top perimeter is shown inFIGS. 79 to 80 for a larger block suitable for an external wall.

Whilst the use of tie clips to interlock wall sections at joins betweenexternal and internal walls has been previously described, it is to beappreciated that other ways of ‘keying in’ the walls may be used as analternative. In one example, as shown in FIGS. 81 to 82 , a cut-out orgroove 15A is routed into a side face of the body 15 of an externalblock 13 proximate and aligned with one of the cores. The width of thecut-out is substantially the same as the width of an internal block sothat during assembly an end 23 of an internal block 11 is inserted intothe groove to thereby tie the blocks together. This may be repeated oneach course or on at least alternating courses.

An alternative and preferred method of keying in the blocks is shown inFIGS. 83 to 85 . In this example, a wall assembly 500 is showncomprising an external wall 510 joined to an internal wall 520. Theinternal wall 520 is tied into the external wall 510 by insertinginternal blocks 11 between adjacent external blocks 13 for at leastalternating courses of blocks so that ends of the internal blocks 11 layflush with an outer face 511 of an external wall 510. Internal blocks 11of the other courses may be in abutment with an inner face 512 of theexternal wall 510. Preferably, internal blocks 11 that extend to theouter face 511 of the external wall 510 are laid onto external blocksbelow (and external blocks laid above) so that the hollow cores of theinternal blocks are aligned with the hollow cores of the externalblocks. As a result, the internal blocks are usually offset from centrewith regard to the external blocks located above and below.

Described herein is a block which is well suited to use in an automatedbrick laying machine, and a wall assembly constructed from the blocksvia such a machine.

Throughout this specification and claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” or “comprising”, will be understood to imply the inclusionof a stated integer or group of integers or steps but not the exclusionof any other integer or group of integers.

Persons skilled in the art will appreciate that numerous variations andmodifications will become apparent. All such variations andmodifications which become apparent to persons skilled in the art,should be considered to fall within the spirit and scope that theinvention broadly appearing before described.

The claims defining the invention are as follows:
 1. A building systemcomprising: a plurality of blocks manufactured in two sizes, configuredfor use in automated building construction, the two sizes of blocksbeing defined by a first block and a second block each with an elongatecuboid body having: a) a height extending between a top and a base,which is substantially identical for the first block and the secondblock; b) a length extending between a pair of opposed ends, which issubstantially identical for the first block and the second block; c) awidth extending between a pair of opposed sides, the second block havinga width at least twice that of the first block, and wherein a surfacearea of a side is greater than a surface area of the top, base or end;and, d) a plurality of hollow cores extending from said top to saidbase, and arranged in a single row between said opposed ends; whereineach core has a substantially identical rectilinear cross-sectionalshape, wherein a length of each core is substantially the same for thefirst block and the second block, and a width of each core in the secondblock is greater than that of each core in the first block; wherein, athickness of each block between each pair of adjacent cores is at leastdouble a thickness of the block on all other sides of each core, so thateach block is divisible by transverse cutting midway between adjacentcores into a plurality of block portions, each block portion includingfour peripheral walls of substantially uniform wall thickness about oneor more cores of the block portion, which is substantially identical forthe first block and the second block, wherein each block includes atleast one rectangular recess configured to accommodate arectangular-section tie plate, the at least one rectangular recesslocated on a top face of the block.
 2. The block building systemaccording to claim 1, wherein the walls extending about the cores areone of: a) substantially solid; and b) include a plurality of secondarycores extending from said top to said base, the secondary coresseparated by a plurality of webs.
 3. The building system according toclaim 1, wherein both blocks include four hollow cores, so as to bedivisible into four substantially identical block portions.
 4. Thebuilding system according to claim 1, wherein the cores of the firstblock comprise a square cross-sectional shape.
 5. The building systemaccording to claim 1, wherein the cores of the second block comprise arectangular cross-sectional shape.
 6. The building system according toclaim 1, wherein the first block is for use in constructing an internalwall, the first block having: a) a length of approximately 490 mm (19inches); b) a width of approximately 115 mm (4.5 inches); c) a height ofapproximately 230 mm (9 inches); and, d) a dry mass of approximately 10to 14 kg (22 to 31 lbs).
 7. The building system according to claim 1,wherein the second block is for use in constructing an external wall,the second block having: a) a length of approximately 490 mm_(19inches); b) a width of approximately 240 mm (9.4 inches); c) a height ofapproximately 230 mm (9 inches); and, d) a dry mass of approximately 17to 22 kg (37.5 to 48.5 lbs).
 8. The building system according to claim1, wherein each hollow core is spaced evenly from each of the opposedsides, and the hollow cores adjacent each end are spaced evenlytherefrom.
 9. The building system according to claim 1, wherein eachblock includes at least one tongue located at one of the opposed ends,and at least one groove located at the other of the opposed ends, eachgroove being provided to at least partially accommodate a tongue of anadjacent one of the blocks, wherein each tongue and each groove extendvertically from the top to the base of the block.
 10. The buildingsystem according to claim 1, wherein the at least one rectangular recessextending one or more of: i) transversely between a hollow core and aside of the block; ii) longitudinally between a hollow core and an endof the block; and, iii) longitudinally between hollow cores of theblock.
 11. The building system according to claim 1, wherein both thefirst block and the second block, or any divisible block portion ofeither, is for use in constructing a wall in accordance with a gridsystem based on the size of the smallest divisible block portion whichenables the cores of each block or divisible block portion in adjacentcourses of the wall to be aligned so as to form conduits inside the wallfor carrying services for the building.
 12. The building systemaccording to claim 1, wherein each block is manufactured from a mixtureincluding at least: a) water; b) cement; and, c) a lightweight expandedaggregate being one of: i) an expanded clay aggregate; ii) an expandedslate aggregate; iii) an expanded shale aggregate; and iv) an expandedglass aggregate.
 13. The building system according to claim 12, whereinthe mixture further includes one or more of: a) a plasticizer; and b) afine aggregate.
 14. The building system according claim 12, wherein thelightweight expanded aggregate is a lightweight expanded clay aggregate(LECA) having particles of diameter at least one of 0 mm-1 mm (0 to 0.04inches), 1 mm-2 mm (0.04 to 0.08 inches), 2 mm-3 mm (0.08 to 0.12inches), 3-4 mm (0.12 to 0.16 inches), 4 mm-5 mm (0.16 to 0.2 inches), 5mm-6 mm (0.2 to 0.24 inches), 7 mm-8 mm (0.24 to 0.28 inches), 8 mm-9 mm(0.28 to 0.32 inches) and 9 mm-10 mm (0.32 to 0.36 inches).
 15. A wallassembly utilizing the building system according to claim 1, comprisingthe a plurality of blocks laid in a plurality of courses, and anadhesive applied between each course of blocks and a successive courseto bond these.
 16. The wall assembly according to claim 15, furtherincluding one or more block portions divided from a block or a remainderthereof by a cut made at a midpoint between adjacent cores.
 17. The wallassembly according to claim 15, wherein cores of blocks in the wallassembly are used as conduits for carrying services for a building. 18.The wall assembly according to claim 15, further including a renderapplied to at least external surfaces thereof.
 19. The wall assemblyaccording to claim 18, wherein the render is an acrylic non-porousrender to seal a wall from moisture ingress.
 20. The wall assemblyaccording to claim 15, wherein the adhesive is machine applied to thebase of a block before being laid onto a lower course.
 21. The wallassembly according to claim 20, wherein at least two parallel beads ofadhesive are applied onto the base of a block along a lengthwise extentthereof.
 22. The wall assembly according to claim 20, wherein theadhesive is further applied onto one or more end faces of a block so asto form a perp joint with an adjacent block in a course.
 23. The wallassembly according to claim 15, wherein the wall assembly is assembledusing a plurality of first blocks having a first width and a pluralityof second blocks having a second width twice that of said first widthplus the thickness of the spacing between the blocks.
 24. The wallassembly according to claim 23, wherein the first blocks are internalblocks that are used substantially in the construction of internal wallsand the second blocks are external blocks that are used substantially inthe construction of external walls.
 25. The wall assembly according toclaim 24, wherein internal walls are tied into external walls by atleast one of: a) inserting internal blocks between adjacent externalblocks for at least alternating courses of blocks so that ends of theinternal blocks lay flush with an outer face of an external wall; b)forming a cut-out in an inner face of one or more external blocks andlocating an internal block into the cut-out to thereby interlock theblocks; and c) by tie clips used in one or more of the courses.
 26. Thewall assembly according to claim 24, wherein internal walls are tiedinto external walls so that overlapping hollow cores of respectiveinternal and external blocks are substantially aligned.